Method of and apparatus for splicing web material



1965 o. s. cvAcHo ETAL 3,

METHOD OF AND APPARATUS FOR SPLICING WEB MATERIAL n61 3 S g mm om Filed July 18, 1962 vm mm mE Nm mm O? INVENTORS DANIEL S. CVACHO WILLIAM C. WHITAKER BY m), fl w #1 THEIR ATTORNEYS United States Patent 3,223,061 METHOD OF AND APPARATUS FOR SPLICING WEB MATERIAL Daniel S. Cvacho and William C. Whitaker, Chesterfield County, Va., assiguors to Reynolds Metals Company,

Richmond, Va., a corporation of Delaware Filed July 18, I962, Ser. No. 210,791 8 Claims. (Cl. 113-120) This invention relates to a method of and apparatus for splicing web or strip material for use in the formation of web or strip material into various constructions.

For example, this invention may be used for forming tubing and the like from a plurality of coils or packages of relatively long strips or webs of forming material.

An active strip from an active coil or package, from which the strip is being actively removed for use in the forming method or apparatus, may be fed through a feeding means to a strip accumulator and through forming means for forming tubing and the like. An excess of active strip may be accumulated in the accumulator before the active coil or package is exhausted, and before the trailing end of said active strip reaches the feeding means in the neighborhood of the accumulator. When the trailing end reaches such neighborhood, the feed of the small remaining portion of the active strip and said trailing end is arrested. The excess strip which was accumulated on the accumulator may then be continuously fed from the accumulator to the forming means to maintain the forming means in operation.

While this excess is being fed, a leading end of a substitute strip from a substitute coil or package is secured to said trailing end before said excess of strip is exhausted from the accumulator. Thereafter the small remaining portion of the active strip and said substitute stri may be continuously fed to the accumulator and to the forming means in the same manner that the active strip previously was fed.

The strip material may be formed into tubing which may be cut into relatively short tubes, or the strip may be formed into relatively short strip formed units or articles of any desired shape and character.

The relatively short tubes or relatively short strip formed units may have matching labels formed from label patterns on the strips. The label patterns may be repeating patterns on the strip and may be applied to each of the short tubes or other small units. The trailing end and the leading end may be secured together in a manner to maintain the continuity and accuracy of the repeating pattern between the active strip and the substitute strip. The trailing end and the leading end may be overlapped with the label patterns matched, and then such overlapping ends may be cut to form abutting ends. Any severed overlapping material may be discarded and then the abutting ends may be butt welded together before the joined strips are fed to the accumulator and the forming means.

If desired, the butt weld may be smoothly finished or ground before being fed to the forming machinery.

Accordingly, an object of this invention is to provide a method, including the splicing or joining of strip material, having one or more of the features herein disclosed.

Another object of this invention is to provide apparatus, including the splicing or joining of strip material, having one or more of the features herein disclosed.

Other objects are apparent from this description, from the appended claimed subject matter, and from the accompanying drawings, in which:

FIGURE 1 is a diagrammatic representation of an apparatus and method embodying this invention.

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FIGURE 2 is a top view of the end clamping means and of the ends of the strips being clamped therein.

FIGURE 3 is a diagrammatic vertical cross section along the line 33 of FIGURE 2.

FIGURE 4 is a view similar to FIGURE 3 and showing the overlapped strip ends being severed.

FIGURE 5 is a view similar to FIGURE 4 and showing the strips having been severed and the excess material being discarded.

FIGURE 6 is a view similar to FIGURE 5 and showing the strips butt welded together.

FIGURE 7 is a vertical cross section along the line 7-7 of FIGURE 2.

FIGURE 8 is a diagrammatic representation of two overlapped strips in which the repeating label patterns have been matched.

FIGURE 9 is a view of the butt welded joint after being smoothly finished.

Certain words indicating direction and relative position are used in this application for the sake of brevity and clearness. It is to be understood, however, that such words apply only to the drawings, and that the actual parts or devices described thereby may have different directions or relative position in actual use. Examples of such words are upper, lower, vertical, horizontal, etc.

According to this invention a web or strip feeding and splicing means 20 may feed a web or strip to a strip accumulator 22. The accumulator 22 may feed the strip to the forming means such as tube forming means 24. The means 24 may form any desired product, such as tubing, and the like 26. The tubing or other product 26 may then be formed or cut into relatively short strip formed units or tubes 28 which may be delivered to the place of use 30, as desired.

A plurality of coils or packages 32, 34, etc., may be used and may contain relatively long strips of suitable forming material. The material may be a metallic material, such as aluminous material, and the like, which may be welded, or it may be any other type of material which may be formed and secured together in any suitable manner. Other coils 36 may be placed on the adjacent conveyor 38 and are in standby readiness for use in the feeding and splicing means 20.

The coil 32 may be the temporarily active coil actively feeding a temporarily active strip 40 to the strip end securing means 42.

Eventually the temporarily active coil 32 becomes exhausted and the trailing end 44 of the strip 40 eventually arrives at the feeding means 20 in the neighborhood of'the accumulator 22, such as at the strip end securing means 42.

However, while the active strip 4% was being fed to the accumulator 22 and from the accumulator 22 to the forming means 24, an excess of active strip 40 was being accumulated in the accumulator 22 before the trailing end 44 of the active strip 40 arrived at'the end securing means 42 in the neighborhood of the accumulator 22.

When the trailing end '44 arrives at the strip end securing means 42, the feed of the small remaining end portion of the active strip 40 and of the trailing end 44 is arrested by the feed stopping or controlling means 46. The accumulator '22, however, continuously feeds the excess of the strip material in the accumulator 22 to the forming means 24 under the control of a forming means feeder 48, to maintain a continuous operation of the forming means 24.

While the feed of strip 40 is arrested at stopping means 46, the trailing end 44 of the active strip 40 and the leading end 50 of the substitute strip 52 are secured together at the securing means 42 before the excess of strip in the accumulator 22 is exhausted. After the ends 44 and 50 are secured together, the remaining end portion of the active strip 40 and the substitute strip 52 are fed to the accumulator 22 and to the forming means 24 in the same manner that the previously active strip 40 previously had been fed.

The substitute strip 52 is fed to the securing means 42 from the substitute coil or package 34. The strip 52 is then fed to the accumulator 22 and the forming means 24 in the same manner as the active strip 46 previously was fed. The strip 52 then becomes the new active strlp, and, if desired, another coil or package 36 may be placed on the mounting means or coil holding means 54 from which the previously active coil 32 may be removed. Such additional coil then becomes the future substitute coil for the future active coil 34 after the coil 34 becomes exhausted.

The spools or packages may be mounted on the spool or package holders 54 and 56. These holders may be in the same vertical plane, so the strips 48 and 52 are fed in proper vertically overlapping condition, so that they may be accurately secured together in the securing means 42.

FIGURES 1 and 2 show the leading end 50 of the strip 52 inserted in the open clamping means 58 waiting for the arrivel of the trailing end 44 of strip 40.

The securing means 42 may take the form disclosed in FIGURES 2 through 8, if desired. For example, the strip ends 44 and 50 may be carefully overlapped, as shown in FIGURE 3, and may then be rigidly held in clamped condition in the clamping means 58. The ends 44 and 50 may then be cut and trimmed by the transverse cutting means or cutter members 60 and 61 as in FIGURE 4, so that cut and trimmed ends 44' and 50' in FIGURE are in abutting relationship at 62 and so the severed overlapping ends 50 and 44" may be discarded.

Thereafter the abutting ends 44' and 50', FIGURE 6, are butt welded together at 64 by the welding means 66.

After the weld 64 is complete and firm, the clamping means 58, in FIGURE 6, may be unclamped, so the welded strips 40 and 52 may be forwarded to the smooth finishing means 68, where the butt weld 64, FIGURE 6, may be finished to provide a smooth butt welded joint which will not interfere with the future processing of the strip material. For example, the smooth finishing means may include a pair of polishing or finishing rolls 7 0 which may be moved transversely of the strip by a movable carriage 72, so the entire joint 64 may be properly smoothed and polished, as shown at 64 in FIGURE 9.

The relatively short tubes or other units 28 may have matching short unit or tube labels, such as the labels diagrammatically indicated by the crossed line ornamentation 74 in FIGURE 8. If desired, the labels may have repeating patterns, as indicated diagrammatically at 74, and each pattern '74 may be applied to a respective tube or other unit 28. The length of the patterns '7 4 from dividing Zone 76 to dividing zone 76 may be of the same length as the tube or unit 28, so the label patterns 74 may be matched and synchronized with the tube or units 28.

The clamping means 58 may be of a nature that the overlapping ends 50 and 44, FIGURE 8, may be secured together in a manner to maintain the continuity and accuracy of the repeating patterns 74 between the active strip 40 and the substitute strip 52. Such continuity is obtained by properly governing the overlap so that the patterns 74 properly overlap each other to maintain the continuity.

The clamping means 58 may include a rectangular frame which is open in the center 82, so the proper cutting and welding actions may be produced. For example, a pair of end frame members 78 and a pair of side frame members 80 may be provided to surround an open center 82. A pair of stationary lower clamping members 84 may be formed by the top surfaces of members 80 and a pair of vertical reciprocal clamping members 86 may be provided. These pairs may be rigidly connected to and spaced from others by a suitable rigid frame. The vertical reciprocal clamping members 86 are slidable in grooves 87 in end frame members 78 and are upwardly biased by springs 88 which are located in the lower parts of grooves 87. Rotatable earns 92 are carried by shafts 94. The shafts 94 are rotated by handles, cranks, or the like 96. The shafts 94 are rotatably mounted and held by bearing members 97 on the tops of end frame members 78.

The construction of the clamping means is such that the trailing end 44 of the active strip 40 may be clamped by the leftward clamps 84 and 86, FIGURE 3, and the leading edge 50 of the substitute strip 52 may then be clamped by the righthand clamping members 86 and 84. If a pattern is to be matched, as shown at 44 in FIGURE 8, then one or both of the overlapping portions of the ends of the strips 40 and 52 may be so adjusted lengthwise of the strips so the pattern 74 at the overlapping edges 44 and 50 are matched, as shown in FIGURE 8. The repeating label pattern 74 is then maintained continuously and without lengthwise distortion, as the two strips are sent forward to the accumulator 22 and the forming machinery 24.

If desired, the clamping means 58 may be supported on wheels 98 which in turn may be supported on trackways 100, so the clamping means 58 may be moved horizontally back and forth from a position between the cutters 60 and 61 to a position between the welding means or heads 66.

The accumulator 22 may include stationary rolls or pulleys 102 and 104 which guide the strip 40 and later the strips 52, etc. These rolls may be supported on stationary framework 106. A leftwardly biased carriage 108 is horizontally movably supported on the trackway 110. The carriage 108 carries a roll 112 around which the strip material passes. The carriage 108 may be leftwardly biased by a motor construction 114, which tends to drive the carriage 108 leftwardly with a sliding clutch construction which permits the carriage speed to adjust to the arresting and excess feed actions at 46 and 48. A control button 116 is engaged by the carriage 108 when the accumulator 22 has accumulated the maximum amount of strip material desired. The control button 116 may stop the motor construction 114 as long as the button 116 is engaged and it also may be connected by the line 118 with the feed stopping means or feed controlling means 46, to cause such feed means 46 to stop or slow down when the accumulator 22 has accumulated the maximum amount of strip material, when the carriage 108 has contacted the button 116.

The feed stopping means or feed controlling means 46 may include a pair of rolls 120 and 122 which are controlled by the member 124. Member 124 may be responsive to the button 116 and it also may be actuatable manually to stop the rolls 120 and 122 when it is desired to splice the ends 44 and 50. The rolls 120 and 122 are stopped when the trailing end 44 is to be clamped in the leftward clamps 84 and 86 with the clamping member 58 under the cutting means 60. However, if desired, the clamping member 58 may have a position, not shown, to the right of the cutters 60 and 61 where the matching and clamping of the ends 44 and 50 may be performed. The cutting means 60 and 61 may be a pair of vertically movable cutting members or knives 60 and 61. When it is desired to move the clamping means between the cutters 60 and 61 and between the welding means 66, 66, the controller 124 may be operated to inch the strips 40 and 52 leftward along with the clamping means 58 to desired positions so the cutters 60, 61 and welding means 66, 66 may cut and weld the abutting ends to form the butt weld 64. Thereafter, the clamping means may release the strips 40 and 52, which then may be advanced so the butt weld 64 may be placed between the finishing rolls 70 to finish the weld 64 into a smooth weld 64', as shown in FIGURE 9.

Theforming means 24 may have a feeder 48 which may include -a pair of rolls 130 and a controller 132. The controller 132 may be subject to control by a control means 134 which is responsive to the action of the forming means 24, so the rolls 130 have a controlling or braking action performed on them to control the passage of the strip 40, and subsequent strips 52, etc., into the forming means 24.

The controls of the rolls 130 are such that they move slightly slower normally than the rolls 120 and 122, so that an excess of strip material is fed to the accumulator 22 over the amount that is moved by the rollers 130 to the machinery 24, Thiscauses the accumulator 22 to accumulate an excess of strip material bythe leftward movement of the carriage 108 so that long runs of strip material 40A and 40B between the rolls 102 and 104 and the rolls 112 are accumulated. These runs 40A and 40B become shorter as the accumulated strip material is used up during a splicing operation.

When the excess strip material in accumulator 22 is to be used to supply the forming means 24 the carriage 108 gradually moves rightward by the pulling action which the machinery 24 and the rolls 130 exert against the stopped rolls 120, 122, which pulling action is more powerful than the leftward bias of the carriage 108 under the slipping clutch means of the motor 114.

It is thus to be seen that a new and useful method and apparatus have been provided in which an accumulator accumulates excess strip material for use during the splicing actions which are necessary when the spools or packages 32, 34, 36, etc., are exhausted and replaced by subsequent spools or packages. The splicing actions are accomplished in a manner which permits an accurate and workmanlike splice construction. If any label patterns are present on the strips, the continuity of such label patterns may be accurately maintained by the label matching procedure obtainable by this invention.

While the form of the invention now preferred has been disclosed, as required by statute, other forms may be used, all coming within the scope of the claims which follow:

What is claimed is:

1. The method of forming tubing and the like from a plurality of coils of relatively long strips of tube forming material which comprises: continuously feeding an tubing; accumulating an excess of active strip in said accumulator and through tube forming means to form said tubing; accumulating an excess of active strips in said accumulator before a trailing end of 'said active strip is in the neighborhood of said accumulator; arresting the feed of a remaining end portion of said active strip and said trailing end to said accumulator while continuously feeding said excess from said accumulator to said tube forming means; clamping a leading end of a substitute strip from a substitute coil to said trailing end in overlapping relationship at two longitudinally rigidly spaced places in a cutting zone; cutting said strips transversely between said spaced places in said cutting zone to produce severed overlapping material and trimmed abutting ends of said strips; removing said severed overlapping material; simultaneously moving said longitudinally rigidly spaced clamped strips with said clamped and abutting ends longitudinally to a welding zone; weld-ing said trimmed abutting ends of said strips in said welding zone before said excess is exhausted from said accumulator; and then continuously feeding said remaining end portion of said active strip and said substitute strip to said accumulator and tube forming means in the same manner that said active strip previously was fed.

2. The method of forming tubing and the like from a plurality of coils of relatively long strips of tube forming material which comprises: continuously fee-ding an active strip from an active coil through a strip accumulator and through tube forming means to form said tubing; accumulating an excess of active strip in said accumulator before a trailing end of said activestrip is in the neighborhood of said accumulator; arresting the feed of a remaining end portion of said active strip and said trailing end to said accumulator while continuously feeding said excess from said accumulator to said tube forming means; clamping a leading end of a substitute strip from a substitute coil to said trailing end in overlapping relationship at two longitudinally rigidly spaced places in a cutting zone; cutting said strips transversely between said spaced places in said cutting zone to produce severed overlapping material and trimmed abutting ends of said strips; removing said severed overlapping material; simultaneously moving said longitudinally rig-idly spaced clamped strips with said clamped and abutting ends longitudinally to a welding zone; welding said trimmed abutting ends of said strips in said welding zone before said excess is exhausted from said accumulator; and then continuously feeding said remaining end portion of said active strip and said substitute strip to said accumulator and tube form-ing means in the'same manner that said active strip previously was fed, in which said tubing is cut into relatively short tubes, and in which said relatively short tubes have matching short tube labels formed from label patterns on said strips, and in which said label patterns are repeating patterns applied to each of said short tubes, and in which said trailing end and said leading end are secured together to maintain the continuity of said repeating patterns between said active strip and said substitute strip, and in which said trailing end of said active strip and said leading end of said substitute strip are overlapped with said label patterns matched and said overlapped ends are cut to form abutting ends, discarding severed overlapping material, and butt welding said abutting ends together before continuously feeding said remaining active strip and substitute strip to said accumulator and'forming means.

3. A method of forming relatively short strip formed units from a plurality of relatively long strips of forming material which comprises: continuously feeding an active strip through a strip accumulator and through a unit forming means; accumulating an excess of active strip in said accumulator before a trailing end of said active strip is in the neighborhood ofsaid accumulator; arresting the feed of a remaining end portion of said active strip and said trailing end to said accumulator while continuously feeding said excess from said accumulator to said unit forming means; clamping a leading end of a substitute strip to said trailing end in overlapping relationship at two longitudinally rigidly spaced places in a cutting zone; cutting said strips transversely between said spaced places in said cutting zone to produce severed overlapping material and trimmed abutting ends of said strips; removing said severed overlapping material; simultaneously moving said longitudinally rigidly spaced clamped strips with said clamped and abutting ends longitudinally to a welding zone; welding said trimmed abutting ends of said strips in said welding zone before said excess is exhausted from'said accumulator; and then continuously feeding said remaining end portion of said active strip and said substitute strip to said accumulator and forming means in the same manner that said active strip previously was fed.

4. In combination: tube forming means; a strip accumulator continuously to feed a tube forming material strip to said forming means; a strip feeder to feed a tube forming material strip to said accumulator at a rate to accumulate an excess of strip in said accumulator; package support means to support a plurality of packages of relatively long strips of tube forming material sequentially to supply said relatively long strips to said strip feeder each with a leading strip end and a trailing strip end; trailing strip end and leading strip end clamping means between said package support means and said strip feeder, said clamping means clamping a trailing end of an active strip to the leading end of a substitute strip -tion to provide severed overlapping material and trimmed abutting ends of said strips; welding means at a welding position to which said clamps are simultaneously movable with said clamped and abutting ends, where said abutting ends are held while being welded together by said welding means; and means to stop said strip feeder from feeding strip to said accumulator while said trailing strip end and said leading end are being cut and welded and While said accumulator continuously feeds strip to said forming means from said excess of strip in said accumulator, and thereafter to feed said welded ends and said substitute strip to said accumulator in the same manner that said active strip previously was fed.

5. In combination: tube forming means; a strip accumulator continuously to feed a tube forming material strip to said forming means; a strip feeder to feed a tube forming material strip to said accumulator at a rate to accumulate an excess of strip in said accumulator; package support means to support a plurality of packages of relatively long strips of tube forming material sequentially to supply said relatively long strips to said strip feeder each with a leading strip end and a trailing strip end; trailing strip end and leading strip end clamping means between said package support means and said strip feeder, said clamping means clamping a trailing end of an active strip to the leading end of a substitute strip in a cutting zone; cutting means to cut said clamped ends in said cutting zone; means to move said clamping means longitudinally to a welding zone; welding means to weld said clamped and cut ends together at said welding zone; and

Y means to stop said strip feeder from feeding strip to said accumulator while said trailing strip end and said leading end are being cut and welded and while said accumulator continuously feeds strip to said forming means from said excess of strip in said accumulator, and thereafter to feed said welded ends and said substitute strip to said accumulator in the same manner that said active strip previously was fed, and in which cutting means are provided to cut the tube formed in said tube forming means into relatively short tubes, and in which said cutting means cuts said short .tubes with matching short tube labels formed from label patterns on said strips, and in which said label patterns are repeating patterns applied to each of said short tubes, and in which said clamping means has means to maintain the continuity of said repeating patterns between said active strip and said substitute strip, and in which said clamping means, cutting 'means and welding means have means to hold said trailing end and said leading end with said ends overlapped, with said label patterns matched, with said overlapped ends cut to form abutting ends, with severed overlapping material discarded and with said abutting ends welded together before feeding said joined ends and said substitute strip to said accumulator, and .in which said clamping means, cutting means and welding means include movable clamping means to clamp said trailing and leading ends while being overlapped, cut and welded.

'6. In combination: a strip feeder; package support means to support a plurality of packages of relatively long strips of forming material sequentially to supply said relatively long strips to said strip feeder each with a leading strip end and a trailing strip end; trailing strip end and leading strip end longitudinally movable clamping means between said pack-age support means and said strip feeder, said clamping means clamping a trailing end of an active strip to a leading end of a substitute strip; in overlapping relationship, said clamping means having a pair of strip clamps rigidly spaced from each other to receive and clamp said overlapping strip ends; cutting means to out said overlapped strip ends at a cutting position to provide severed overlapping material and trimmed abutting ends of said strips; welding means at a welding position to which said clamps are simultaneously movable with said clamped and abutting ends, where said abutting ends are held while being welded together by said welding means; and means to stop said feeder while said trailing end is being cut with, and welded to said leading end.

7. In combination: a pair of strip spool holders in the same vertical plane; a pair of strip clamps horizontally spaced from each other, rigidly connected to each other, and horizontally movable between a cutting position and welding position in said same horizontal plane to receive and clamp overlapping strips from strip spools on said strip holders; transverse cutter members in said cutting position between which said overlapping strips are held by said clamps to cut said overlapping strips to produce aligned butting edges of said strip; and welding means in said welding position to which said aligned butting edges may be moved and held by said strip clamps while said edges are being welded by said welding means.

8. In combination: a pair of strip package holders; a pair of strip clamps rigidly spaced from each other and simultaneously movable to a cutting position to receive and clamp overlapping strip ends from a pair of strip packages respectively held in said holders; cutting means at said cutting position to cut said overlapped strip ends at said cutting position [to produce severed overlapping material and trimmed abutting ends of said strips; welding means at a welding position to which said clamps are simultaneously movable with said clamped and abutting ends, where said abutting ends are held while being welded together by said welding means and a strip feeder and controller receiving the Welded strips from said clamping means and having means to stop the feed of said strip while said ends are being joined.

References Cited by the Examiner UNITED STATES PATENTS 1,795,380 3/ 1931 Stresau l1 335 2,120,316 6/1938 Stone 113l23 2,549,032 4/1951 Taylor 11335 2,623,443 12/ l952 Robinson 93-80 2,748,734 6/1956 Kennedy 113-33 3,024,157 3/1962 Beerli 24258.1 3,042,332 7/ 1962 Astley 24258.3 3,057,056 /1962 Foley et al 113-423 CHARLES W. LANHA-M, Primary Examiner.

' WILLIAM J STEPHENSON, Examiner. 

1. THE METHOD OF FORMING TUBING AND THE LIKE FROM A PLURALITY OF COILS OF RELATIVELY LONG STRIPS OF TUBE FORMING MATERIAL WHICH COMPRISES: CONTINUOUSLY FEEDING AN ACTIVE STRIP FROM AN ACTIVE COIL THROUGH A STRIP ACCUMULATOR AND THROUGH TUBE FORMING MEANS TO FORM SAID TUBING; ACCUMULATING AN EXCESS OF ACTIVE STRIP IN SAID ACCUMULATOR BEFORE A TRAILING END OF SAID ACTIVE STRIP IS IN THE NEIGHBORHOOD OF SAID ACCUMULATOR; ARRESTING THE FEED OF A REMAINING END PORTION OF SAID ACTIVE STRIP AND SAID TRAILING END TO SAID ACCUMULATOR WHILE CONTINUOUSLY FEEDING SAID EXCESS FROM SAID ACCUMULATOR TO SAID TUBE FORMING MEANS; CLAMPING A LEADING END OF A SUBSTITUTE STRIP FROM A SUBSTITUTE COIL TO SAID TRAILING END IN OVERLAPPING RELATIONSHIP AT TWO LONGITUDINALLY RIGIDLY SPACED PLACES ING A CUTTING ZONE; CUTTING SAID STRIPS TRANSVERSELY BETWEEN SAID SPACED PLACES IN SAID CUTTING ZONE TO PRODUCE SEVERED 